Nondestructive Testing (NDT) Plugs are engineered to allow repeat access for EPA/OSHA inspection and process safety management.
Plugs can be installed on insulated and non-insulated pipe, storage tanks, pressure vessels and petrochemical, oil and gas, steam and nuclear power generation facilities.
Engineered NDT2 inspection plugs consist of an elastomer sleeve, metal handle, metal cap, lanyard* and locking ring.
The elastomer sleeve consists of ethylene propylene (EPDM) or silicone (higher temps).
The metal caps can be 304 stainless steel or 5052 aluminum depending on the application.
* Note: lanyards are particularly useful in overhead conditions to prevent the cap from falling if dropped.
Regular access to pipes and equipment benefits areas of process safety management:
Safety NDT inspection plugs allow inspectors to safely access the inside of insulated pipes and equipment without removing the insulation. This helps to ensure the safety of the piping system.
Accuracy NDT inspection plugs help to ensure that thickness measurements are accurate. They also standardize the location of thickness measurements, which helps to protect the integrity of inspection data.
Time NDT inspection plugs reduce the time required for periodic inspections and tests. Once installed, access often.
Corrosion NDT inspection plugs provide a seal that can help protect against corrosion under insulation (CUI), chemical and UV exposure.
Condition Monitoring (CM): the process of monitoring specific parameters (like vibration, temperature, lubricant condition, etc.) of critical equipment or systems to detect any significant change which might indicate a developing fault.
It’s a “snapshot” of the current condition at a particular time.
Predictive Maintenance (PdM): involves using data-driven, pro-active maintenance methodologies to predict when equipment failure might occur, so maintenance can be performed just in time to avoid unplanned downtime.
Predictive Maintenance often uses the data obtained from Condition Monitoring, but appliesanalytics, algorithms, and sometimes machine learning to predict future failures.
Maintenance vs. Monitoring
Purpose: CM: Detect and monitor changes in machine conditions to highlight potential problems.
PdM: Forecast when a machine will fail or when a maintenance task should be performed to prevent an unplanned outage.
Method: CM: Regular or continuous measurement of equipment parameters and comparison against predefined standards or baselines.
PdM: Analysis of data trends and patterns (often with the help of advanced software tools) to predict the future condition of the equipment and schedule maintenance accordingly.
Frequency: CM: Monitoring can be continuous, daily, weekly, monthly, etc., depending on the criticality of the equipment.
PdM: The frequency is determined by data trends and the analytics’ outcomes, leading to predictions on when maintenance might be required next.
Digital Radiography: The use of digital imaging techniques for radiographic testing, which offers improved sensitivity and resolution compared to traditional film-based methods.
Eddy Current Testing (ECT): ECT is widely used for surface and near-surface defect detection, and advancements in probe design and signal processing have increased its applicability.
Phased Array Ultrasonics: This is a specialized ultrasonic testing technique that employs multiple small ultrasonic elements to steer and focus sound waves, allowing for rapid scanning and defect characterization.
Computed Tomography (CT) Scanning: CT scanning is a powerful technique that provides 3D images of internal structures, making it valuable for inspecting complex components and composite materials.
Infrared Thermography: This technique uses thermal imaging to detect variations in temperature, which can indicate defects or anomalies in materials.
Acoustic Emission Testing (AE): AE is used for continuous monitoring and detection of active defects, crack growth, or structural integrity of components under stress.
Guided Wave Testing (GWT): GWT is used for long-range inspection of pipes, plates, and other structures, allowing for the assessment of large areas from a single probe position.
Electromagnetic Testing (ET): ET includes methods like Magnetic Particle Testing and Eddy Current Testing, which are used for surface and subsurface defect detection.
NDT in Additive Manufacturing: With the growing use of additive manufacturing (3D printing) in various industries, there is an increasing demand for NDT techniques to ensure the quality of printed components.
The NDT Resource Center is an Iowa State University website with a wide-variety of information about Nondestructive Evaluation (NDE) and Nondestructive Testing (NDT).
1) To serve as an educational resource for students and instructors of two-year nondestructive testing (NDT) programs, and others with an interest in NDT technology.
2) To promote NDT as a career field to students, teachers and counselors in junior and senior high schools. And to encourage students to study math and science in preparation for careers in high-technology fields, such as NDT.
3) To serve as a resource for review, reference and sharing of information by the NDT community at-large.
